Intelligent Mining: Integrated Mine Planning and Operations

© ABBSlide 1 May 1, 2023

Intelligent MiningIntegrated Mine Planning and Operations

Rafal Walecki – Head of EMEA Delivery, Mining Solutions, ABB


Challenges & HistoryOur visionABB’s Solution ComponentsHow it all fits together


OUR VISION


Challenges driving shareholders returns

Depleting Reserves

Export Tonnage

Inland Tonnage

Declining Grades

Prim

ary

Gra

de, %

1.5

1.4

1.3

1.2

1.1

0.9

Increasing Costs80

60

40

20

02000 2011

Consumables

Labor

EnergyOther

Source: Xstrata Copper

Ore grade quality is declining

Reserves are depleting in some

commodities. Assets and ore bodies are

becoming more complex.

Labor is more costly, energy costs are going up and the doing business in new markets puts

pressure on margins

The bottom line: how to continue to deliver high returns to shareholders

1980 2000 2020

2000 2015 2030


Step-changes in mining technology

• Standardization of processes

• Mechanization means dramatic shifts in production capabilities

• Operation of equipment still requires human interaction

• Integrated modeling and planning for higher quality yield

• Greater visibility into parts of the value chain

• More detailed information coming from equipment and plant to enable remote mining

• More responsive demand and supply

• Higher level of automation driven by labor shortages and remote mining locations

• Limiting bottlenecks by adopting more continuous processes

• High levels of visibility across the value chain and between operations

Mechanization Automation Optimization

The mining industry has been through a number of technology ‘step-changes’ which

have driven dramatic increases in productivity. Research into mining technologies indicate

significant new technologies heralding the next era of mining productivity


ABB Mining Vision Coverage

To drive fundamental change in the way a Mining Enterprise works, creating dramatic increases in

Health and Safety

Productivity

Predictability

Asset Availability

Energy Efficiency

Quality


Mining Conveyer Asset Health

Temperature sensors detect overcurrent

condition on conveyor drive and create alarm

Control system slows belt speed to reduce

risk of an issue

Work order automatically raises a

parts requisition

Work order is sent to maintenance crew mobile devices and work is completed

Condition, inspection, and work combines for

a unified view of conveyer health and optimization of the

current maintenance programs

1 2 3

456

The old way: No information on upstream

downstream impact Cant prioritize significant data

volumes - manual Production, equipment and

other control systems not integrated

Work order scheduling in disparate systems

No optimization of assets

Value Proposition

Transform real-time and historical asset data into strategic insights on the health of your mission-critical assets.


Mining Plant Operations Optimization

Advanced process control (APC) manages

reagent dosing and flow rates in real-time

(OT)

Geological model and real-time material

tracking provides short term feed

characteristic schedule to APC

Sales system monitors global index pricing for

products

Sales system periodically provides

relative pricing updates to APC

APC refines control set points to maximize returns for current feed material and

product pricing

On stream analyzers in plant reconcile actual

feed with model to further improve

predictability and optimization

1 2 3

567

The old way: No information on relative

product pricing No information on feed

material Plant set points static Production, equipment and

other control systems not integrated

Value PropositionIncrease plant recovery and optimize product mix based on current pricing.

4


SOLUTION COMPONENTS


Solution Components

Plant ReportingMass BalancePlant Efficiency

Material Logistics & Blending

Inventory ManagementSales & Marketing

Enterpise Asset ManagementWork and Projects ManagementMaintenance Management System

Lab ManagementSample Tracking

QA/QC Quality

Geological ModelingMine Planning/SchedulingMine Operations


Geoloigical Modeling & Mine Planning

Geology &Mine Planning

Other Geological Database

Geological Model Excavations Model

Production Scheduling Mine Design

Geological Database

Exp

lora

tion

Survey

Asset & Work Management Product Logistics & Sales


Material Logistics and Sales

Mining Activities

Processing

Transportation

Top Soil Drilling Overburden Waste Dump Parting Removal Loading Hauling Reject Disposal Rehabilitation

ROM StockpilesHauling Processing Plant Product Stockpiles Load Products

Transporting Train Loading Ship LoadingPort StockpilesTrain UnloadingRail Head Stockpiles


Mining Laboratory Management System (LIMS)

Q

B

L Lab Status

QA Flag

Budget / Actual

Sample

Analytical Result

Dispatch

S

AD

Legend

Assay Mgmt LabInstrument

Integration/Interface Layer

ABB CCLAS Modules

LabConfig.

Web Interface, Dashboards & Reporting

BIReporting

Rules User Forms

QA &SPC

ERPSystem

D A AS

DataAudit

SampleRegistrat’n

DataCapture& MDE

DataCalculat’n

Scripting

SampleTracking

LabMaint.

L

Invoice &Revenue

Task Automt’n

Consum-ables

Instr.Mgmt

Archive/Retrieve

A A


Production Accounting

Management Systems (e.g. ERP)

Total production by period, KPIs, qualities, inventories

tons, volume, grade, moisture, hardness, penalty elements - transaction, shift, day, week, month

METAL ACCOUNTING BUSINESS PROCESS

Acquire

Validate

Authorize

Calculate

Report

Publish

Analyze

Audit


Asset Management

Enable PAS 55 Standardize Asset Management practice

Mobile Workforce Management Manage assets from the point of inspection Automate field-based processes Optimize mobile workforce, including 3rd party contractors

Asset Management Paradigms for Critical Assets Manage in terms of both Risk and Criticality Location based asset management with GIS integration

Advanced Work Planning Closed-loop long and real-time work planning and scheduling

Materials Management Total asset visibility Financial fidelity of assets and improved inventory management

Enterprise Visibility Highly flexible, open analytics and reporting


How it fits together – Complete Integration

PA MineScapeCCLAS

• Supply Chain Network Configuration

• Inventory & Stockpile Management• Material Tracking• Waste Dump Management• Outbound Logistics Scheduling• Blending to and Optimization• Port operations & Ship loading• Sales & Invoicing• Shipping documents• Supply & Demand Balancing• Contract Fulfilment & Management• Mining Data Reconciliation

• Transaction assays• Transport assays• Ship loading assays MineMarket

Laboratory Information Management System

Resource block model

Production Schedule

Pit/UG Surveys

Actual Production

Aggregated transactions

Daily stock balance

End of period survey

Reconciled transactions

• Sample ID• Transaction details

Block ID

Assay data

Moisture

Assay data

• Geological DB• Stratmodel• Block model• Opencut design• Underground

design• Ring design• Scheduling• Mine & pit survey• Dragline• Haul roads• Drill & blast

• Auto data acquisition• Auto data validation• Statistical validation• Data checks• Data sign-offs• Auditing• Cascading calculations• Check in – Check out• Statistical balancing• Data locking

(quarantined)• Data publishing

EllipseASSETS Asset Policy Capital Work Register Asset Develop Strategy Deploy Strategy Asset Analysis

WORK Create Plan Schedule Execute Complete Work Analysis

MATERIALS Requirements Source Materials Procure Use Materials Distribution Performance

Analysis

PEOPLE Maintain Organization Workforce Planning Organizational

Development Time & Attendance Pay & Benefits HSSRE

FINANCIAL Financial Model Accounts Payable Accounts Receivable Fixed Assets General Ledger Performance & Compliance

Production S

chedule

Equipm

ent Data

Equip. Availability

Production by period

Quality data

Inventories

Financial & K

PI

Reserves

• Production by period• Stock balance• Equipment delays• Equipment usage• Shipment actuals• Invoicing details

• Budget & Forecasts• Production plans• Contracts details• Shipment schedule• Equipment master


How it fits together - Operations Visibility

VP Health, Safety & Compliance

VP OPS

PERFORMANCE

CFOCIO

VPProcurement

KW-hours/ton

Delay penalties per month

Equipment-incidents /

month

Ship over-under load/month

Drill-blast cost/ton

Reagents/ton

Fuel/ton

Metric per Unit-Product-

Produced

Dig rate by shovel

DilutionAvailability

Throughput

Shipping queue length


How it fits together - Intelligent Operation

Data Processing and Analytics

Subject Matter Workbench

Geology & Mine Planing Product Logistics

Equipment

Performance

Work Parameters

Technical Specifications

Sensors

SCADA

SCAD

A

Feedback Information

Volume

Mass

Quality

Feed

back

ConditionalMonitoring

Operations Control Center

Info

rmati

on

D

ecisi

ons

Results

Historian

Enterprise Data Sources

EAM


How it fits together - One Control Room


FIND OUT MORE

Visit www.abb.com/enterprise-software

Email [email protected]

http://www.abb.com/enterprise-software

mailto:[email protected]

mailto:[email protected]

Intelligent Mining: Integrated Mine Planning and Operations

Software

Transcript of Intelligent Mining: Integrated Mine Planning and Operations